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Originally Posted by stuntbutt  I think those hinges would be beefy enough, but it will probably look like a shed door. |
Well, I'd add the hinges directly to the face of the MDF+MDF, and then add 1/4" paneling on top to completely cover all screws and hinges. You wouldn't see the hinges.
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I still think the way to go is to add layers and seals to an existing door. Here's a basic exterior steel slab door for $105:
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I do agree, I wish I could do that, but in my situation, I only have about 6.5' of height where the doors must go (door openings happen to be under a thick girder), so any standard doors I buy will need to be cut. Cutting those steel skinned doors (and included frame) is not impossible, but generally "messy"... then I'd have to deal with the edge that was cut, will have an open and weak steel skin edge with foam hanging out.
In my specific case, it seems to make more sense to make custom doors from scratch than to buy the steel skinned doors, cut them, and THEN add layers of material to them. Somehow it seems it that making custom doors will be about the same amount of work or possibly even less, and will yield a neater end result, at least if done with care.
I wish I had more height!
